Welding wire container

ABSTRACT

The present invention is a container for welding wire which minimizes surface rust formation on the welding wire.

TECHNICAL FIELD

The present invention pertains to a welding wire container.

BACKGROUND OF THE INVENTION

Spools or reels are well known for transporting and storing bulk wire, cable and/or other wound material such as welding wire, electrical wire, bailing wire, and the like. A typical spool comprises a pair of disc-shaped flanges joined by a central barrel. Wire or cable is spirally wound around the central barrel between the spaced flanges until the spool is filled with the appropriate amount of material. Filled spools can then be stacked atop one another for shipment, storage and subsequent use. When it is desired to dispense the wire or cable, it may be pulled progressively from the spool, which may, for example, be mounted on an arbor or spindle to rotate and thus pay out the wound material. Other pay out methods include laying the spool flat on a flange and using a flyer payoff unit mounted that spins the wire off over the upper flange to pay out the wound material.

Spools used for holding welding wire are typically constructed of a generally cylindrical core or barrel, which can be made from a variety of materials and can come in a variety of different diameters and lengths. Attached at either end of the core are two flanges which are generally round and serve to retain the welding wire on the barrel. The flanges are generally constructed using a lathe which cuts them to shape and cuts a continuous groove on the inner face of both flanges to receive the barrel. The spool is held together by a series of through-bolts that run through drilled holes in one flange, through the barrel, and through drilled holes in the other flange. Spools are typically stored within cardboard containers.

Welding consumables may travel significant distances throughout the world and through disparate climates due to the specificity of each manufacturer and globalization of the market. The welding wires are typically metallic in nature, and containing at least some iron, have a tendency to form metallic oxide or more specifically, iron oxide coatings on the surface (e.g., rust) when exposed to conditions which contain moisture or water vapor. This may affect the welding wire surface and performance. This moisture may be generated through different sources. Typical fiber-type packaging will contain some absorbed humidity. Or water vapor may be released from the atmosphere if the temperature cycle increases over 40° C. In many regions of the world, this happens daily and this temperature cycle (evaporation during the day, condensation at night) leads to surface deterioration of the welding wire.

Some actions may be taken to limit the welding wire degradation risk: desiccant gel to trap moisture; or insertion of a plastic liner around the packaging. However, these actions are limiting the risk; not eliminating it. What is needed, is a welding wire container which does not employ materials which are prone to picking up moisture.

BRIEF SUMMARY

What is illustrated is a welding wire container which includes: a metal cylinder having a diameter, said cylinder having a top and closed at a bottom; a metal spool insertable into said cylinder; the spool having two components: a first spool component having a first spool diameter and a laterally extending flange at one end of the first spool component; and a second spool component having a second spool diameter and a laterally extending flange at one end of the second spool component; each of the flanges dimensioned so as to be insertable into the metal cylinder; the spools dimensioned so as to have one spool diameter insertable into the other spool diameter; and a metal lid dimensioned to fit onto the top of the cylinder.

The lid of the container may include a gasket positioned into a peripheral groove in the lid. The lid also typically includes a plurality of bendable tabs to securingly fasten the lid to the cylinder.

In another aspect of the invention, the welding wire container is made of a plastic material for one or both of the container and/or the spool.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an assembly view of a welding wire container; and

FIG. 2 is a perspective view of the welding wire container of FIG. 1 positioned on a turning table.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawing wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same, FIG. 1 shows a steel drum which is used as a welding wire container. This approach eliminates the fiber core included in traditional welding wire packaging, and replaces it with an accessory mounted at the customer site and reusable from drum to drum. The wire will be transported inside the metallic or plastic drum without any fiber material included, and by employing this construction, will either eliminate (or significantly reduce) the risk of humidity release when the welding wire is submitted to high temperature cycle thereby either eliminating (or at least significantly reducing) the related risks for welding wire surface rust formation.

As illustrated in FIG. 1, cylindrical drum 12 has a bottom 14 and circumferential top edge 16. Dimensioned so as to be insertable inside drum 12 is welding wire spool which is constructed of two parts: bottom spool component 38 and top spool component 40. Bottom horizontal flange 18 of bottom spool component 38 is diametered so as to fit inside cylindrical drum 12. Horizontal flange 18 has an upwardly extending cylindrical collar 20 terminating at an inner circumferential top collar edge 22. Top spool 40 has an essentially top horizontal flange 28 and downwardly extending cylindrical collar 26 terminating at peripheral circumferential edge 24. Cylindrical collar 26 is preferably dimensioned so as to fit inside cylindrical collar 20, although it is recognized that there may be instances where this dimensional relationship may be reversed. In transport, it is recognized that the combination of cylindrical collar 26 and top horizontal flange 28 are optional.

Welding wire is wound about mating cylindrical collars 20, 26. The wound spool is inserted into cylindrical drum 12 and top lid 32 with gasket 30 positioned in a peripheral groove in top lid 32 is affixed to drum 12 by prying at least several of the bendable tabs 34 about circumferential top edge 16 of drum 12, the combination forming welding wire container 10.

In one aspect of the invention, all of the welding wire container component parts illustrated in FIG. 1 are constructed of metal or a metal alloy (e.g., steel, aluminum, etc.), with the exception of gasket 30, which is typically of a rubber (or elastomer) or a silicone compound. In another aspect of the invention, the welding wire container component parts are polymeric in nature, often reinforced to provide the requisite strength characteristics necessary for the application. The polymers may be crosslinked to provide the required rigidity, e.g., crosslinked polyethylene (“PEX”).

Illustrative and non-limiting examples of metals which may be used, include at least ferrous metals and noble metals, each with their associated alloys and various grades.

In use, cylindrical collar 26 and top horizontal flange 28 are inserted into the combination of horizontal flange 18 and upwardly extending cylindrical collar 20 to permit payoff of wound welding wire 36 using turning table 48.

The invention has been described herein with reference to the disclosed embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 

1. A welding wire container which comprises: a metal cylinder having a diameter, said cylinder having a top and closed at a bottom; a metal spool insertable into said cylinder; said spool having two components: a first spool component having a first spool diameter and a laterally extending flange at one end of said first spool component; and a second spool component having a second spool diameter and a laterally extending flange at one end of said second spool component; each of said flanges dimensioned so as to be insertable into said metal cylinder; said spools dimensioned so as to have one spool diameter insertable into the other spool diameter; a metal lid dimensioned to fit onto the top of said cylinder.
 2. The container of claim 1 which further comprises: a gasket positioned into a peripheral groove in said lid.
 3. The container of claim 2 wherein said lid further comprises a plurality of bendable tabs to securingly fasten said lid to said cylinder.
 4. A welding wire container which comprises: a metal cylinder having a diameter, said cylinder having a top and closed at a bottom; a plastic spool insertable into said cylinder; said spool having two components: a first spool component having a first spool diameter and a laterally extending flange at one end of said first spool component; and a second spool component having a second spool diameter and a laterally extending flange at one end of said second spool component; each of said flanges dimensioned so as to be insertable into said metal cylinder; said spools dimensioned so as to have one spool diameter insertable into the other spool diameter; a metal lid dimensioned to fit onto the top of said cylinder.
 5. The container of claim 4 which further comprises: a gasket positioned into a peripheral groove in said lid.
 6. The container of claim 5 wherein said lid further comprises a plurality of bendable tabs to securingly fasten said lid to said cylinder.
 7. A welding wire container which comprises: a plastic cylinder having a diameter, said cylinder having a top and closed at a bottom; a plastic spool insertable into said cylinder; said spool having two components: a first spool component having a first spool diameter and a laterally extending flange at one end of said first spool component; and a second spool component having a second spool diameter and a laterally extending flange at one end of said second spool component; each of said flanges dimensioned so as to be insertable into said metal cylinder; said spools dimensioned so as to have one spool diameter insertable into the other spool diameter; a metal lid dimensioned to fit onto the top of said cylinder.
 8. The container of claim 7 which further comprises: a gasket positioned into a peripheral groove in said lid.
 9. The container of claim 5 wherein said lid is fastenable to a top periphery of said cylinder. 